Method of manufacturing net-shaped bimetallic parts

1. A method of manufacturing a bimetallic part comprising the steps of:

providing a tool that defines a cavity and a tooling surface;

depositing a layer of an environmental metal material onto said tooling surface, wherein said environmental metal material is deposited on said tooling surface to a depth of approximately one half of a largest particle diameter of the powdered metal material;

filling said cavity in said tool with a powdered metal material such that said powdered metal material contacts said environmental metal material; and

simultaneously heating said tool and subjecting said tool to a pressurized gas to compact said powdered metal material and diffusion bond said environmental metal material to said compacted powdered metal material to thereby form said bimetallic part.

2. The method of manufacturing a bimetallic part of claim 1 , wherein prior to heating said tool, the methodology includes the steps of:

degassing said powdered metal material; and

sealing said tool.

3. The method of manufacturing a bimetallic part of claim 1 , wherein after heating said tool, the methodology includes the step of removing said tool from said environmental metal material.

4. The method of manufacturing a bimetallic part of claim 3 , wherein an acid is employed to chemically remove the tool from the environmental metal material.

5. The method of claim 4 , wherein the tool is formed from a ferrous material.

6. The method of manufacturing a bimetallic part of claim 5 , wherein said ferrous material is high purity iron with low carbon content.

7. The method of manufacturing a bimetallic part of claim 1 , wherein said environmental metal material is selected from a group consisting of nickel-based superalloys, iron-based superalloys and 300-series stainless steels.

8. The method of manufacturing a bimetallic part of claim 1 , wherein said powdered metal material is a 720-alloy.

9. The method of manufacturing a bimetallic part of claim 1 , wherein said environmental metal material at least partially forms an outer surface of said bimetallic part.

10. The method of manufacturing a bimetallic part of claim 1 , wherein said environmental metal material is deposited onto said tooling surface using a method from a group consisting of low pressure plasma spraying, wire arc spraying, kinetic energy metallization, direct laser deposition and air plasma spraying.

11. The method of manufacturing a bimetallic part of claim 1 , wherein said bimetallic part is a net-shaped bladed disk.

12. The method of manufacturing a bimetallic part of claim 1 , wherein said powdered metal material indents said environmental metal material during the step of heating said tool and subjecting said tool to a pressurized gas.

13. A method of manufacturing a bimetallic part comprising the steps of:

providing a tool that defines a cavity and a tooling surface;

depositing a layer of an environmental metal material onto said tooling surface, wherein said environmental metal material is deposited on said tooling surface to a depth of approximately one half of a largest particle diameter of the powdered metal material;

filling said cavity in said tool with a powdered metal material such that said powdered metal material substantially fills said environmental metal material; and

hot isostatically pressing said tool to consolidate said powdered metal material and bond said environmental metal material to said consolidated powdered metal material to thereby form said bimetallic part.

14. The method of manufacturing a bimetallic part of claim 13 , wherein said environmental metal material at least partially forms an outer surface of said bimetallic part.

15. The method of manufacturing a bimetallic part of claim 13 , wherein said environmental metal material is deposited onto said tooling surface using a method from a group consisting of low pressure plasma spraying, wire arc spraying, kinetic energy metallization, direct laser deposition and air plasma spraying.

16. The method of manufacturing a bimetallic part of claim 13 , wherein prior to heating said tool, the methodology includes the steps of:

degassing said powdered metal material; and

sealing said tool.

17. A method of manufacturing a bimetallic part comprising the steps of:

providing a tool that defines a cavity and a tooling surface;

depositing a layer of an environmental metal material onto said tooling surface;

filling said cavity in said tool with a powdered metal material such that said powdered metal material contacts said environmental metal material;

simultaneously heating said tool and subjecting said tool to a pressurized gas to compact said powdered metal material and diffusion bond said environmental metal material to said compacted powdered metal material to thereby form said bimetallic part; and

removing said tool from said environmental metal material, wherein an acid is employed to chemically remove the tool from the environmental metal material.

18. The method of manufacturing a bimetallic part of claim 17 , wherein prior to heating said tool, the methodology includes the steps of:

degassing said powdered metal material; and

sealing said tool.

19. The method of claim 17 , wherein the tool is formed from a ferrous material.

20. The method of manufacturing a bimetallic part of claim 19 , wherein said ferrous material is iron.

21. The method of manufacturing a bimetallic part of claim 17 , wherein said environmental metal material is selected from a group consisting of nickel-based superalloys, iron-based superalloys and 300-series stainless steels.

22. The method of manufacturing a bimetallic part of claim 17 , wherein said powdered metal material is a 720-alloy.

23. The method of manufacturing a bimetallic part of claim 17 , wherein said environmental metal material at least partially forms an outer surface of said bimetallic part.

24. The method of manufacturing a bimetallic part of claim 17 , wherein said environmental metal material is deposited onto said tooling surface using a method from a group consisting of low pressure plasma spraying, wire arc spraying, kinetic energy metallization, direct laser deposition and air plasma spraying.

25. The method of manufacturing a bimetallic part of claim 17 , wherein said bimetallic part is a net-shaped bladed disk.

26. The method of manufacturing a bimetallic part of claim 17 , wherein said powdered metal material indents said environmental metal material during the step of heating said tool and subjecting said tool to a pressurized gas.

27. A method of manufacturing a bimetallic part comprising the steps of:

providing a tool that defines a cavity and a tooling surface, wherein the tool is formed from a ferrous material;

depositing a layer of an environmental metal material onto said tooling surface;

filling said cavity in said tool with a powdered metal material such that said powdered metal material contacts said environmental metal material; and

simultaneously heating said tool and subjecting said tool to a pressurized gas to compact said powdered metal material and diffusion bond said environmental metal material to said compacted powdered metal material to thereby form said bimetallic part.

28. The method of manufacturing a bimetallic part of claim 27 , wherein said ferrous material is iron.

29. The method of manufacturing a bimetallic part of claim 28 , wherein said iron has a carbon content that is approximately equal to a carbon content in said environmental material.

30. The method of manufacturing a bimetallic part of claim 28 , wherein said environmental metal material is selected from a group consisting of nickel-based superalloys, iron-based superalloys and 300-series stainless steels.

31. The method of manufacturing a bimetallic part of claim 28 , wherein said powdered metal material is a 720-alloy.

32. The method of manufacturing a bimetallic part of claim 28 , wherein said environmental metal material is deposited on said tooling surface to a depth of approximately one half of a largest particle diameter of the powdered metal material.